Systems and methods for packaging small objects

ABSTRACT

A small object packaging system including a small object container marking and loading station configured to singulate a plurality of small object containers, mark each with at least one information label, and load each marked container into a respective one of a plurality of container transport pallets. The system additionally includes at least one small object counting station configured to deposit a specified amount of small objects into each marked container. The system further includes a capping station configured to secure a cap onto a marked container. The system includes an offloading station configured to remove the loaded containers and place them into a container packing case.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a National Stage of International Application No. PCT/US2012/039036, filed May 23, 2012, which claims priority to U.S. Provisional Application No. 61/489,877, filed on May 25, 2011, the disclosures of which are incorporated herein by reference in their entirety.

FIELD

The present teachings relate to automated systems and methods for packaging small objects, such as seeds, pharmaceutical tablets or capsules, and any other agricultural, manufactured or produced small objects.

BACKGROUND

The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.

The packaging of small agricultural, manufactured and/or produced objects such as seeds, pharmaceutical tablets or capsules, small electrical components, ball bearings, small food products, etc. can be cumbersome, painstakingly tedious, and wrought with human error.

For example, in seed breeding, selected quantities of various types of seeds must be culled from large numbers of various seed types and then packaged for transfer to a storage facility or to the field for planting. Generally, the select amounts of seeds are manually separated from bulk quantities of the selected types of seeds and then manually packaged for transfer to a storage facility or to the field for planting. Hence, such packaging processes are typically painstakingly performed by hand, which is extremely time consuming and subject to human error.

SUMMARY

The present disclosure provides automated systems and methods for packaging small objects, such as seeds, pharmaceutical tablets or capsules, and any other agricultural, manufactured or produced small objects.

In various embodiments, an exemplary small object packaging system is provided that includes a small object container marking and loading station structured and operable to singulate a plurality of small object containers, mark each singulated small object container with at least one information label, and load each marked small object container into a respective one of a plurality of container transport pallets. The system additionally includes at least one small object counting station that is structured and operable to deposit a selected amount of small objects into each marked small object container based on data provided by the respective information label. The system further includes a capping station structured and operable to singulate a plurality of container caps and secure each singulated cap onto a respective marked small object container after the selected amount of small objects have been deposited therein. Furthermore, the system includes an offloading station structured and operable to remove each capped small object container from the respective container transport pallet and place each removed small object container into a container packing case. Still further, the system includes a main hub conveyor structured and operable to transport the loaded container transport pallets from the small object container marking and loading station, to the at least one small object counting station, to the capping station and to the offloading station, and then transport the empty container transport pallets back to the small object container marking and loading station.

In various other embodiments, an exemplary small object packaging system is provided that includes a small object container marking and loading station structured and operable to singulate a plurality of small object containers, mark each singulated small object container with at least one information label, and load each marked small object container into a respective one of a plurality of container transport pallets. Each container transport pallet includes a programmable RFID tag structured and operable to be programmed with information corresponding to information provided by the at least one container specific information label of the respective small object container loaded therein. The system additionally includes a plurality of small object counting stations, each small object counting station structured and operable to deposit a selected amount of a selected type of small objects into selected marked small object containers based on data stored in the respective container transport pallet RFID tag.

The system further includes a capping station structured and operable to singulate a plurality of container caps and secure each singulated cap onto a respective marked small object container after the selected type and amount of small objects have been deposited therein. Furthermore, the system includes an offloading station structured and operable to remove each capped small object container from the respective container transport pallet and place each removed small object container into a selected one of a plurality container packing cases based on data stored in the respective container transport pallet RFID tag. Still further the system includes a main hub conveyor structured and operable to transport the loaded container transport pallets from the small object container marking and loading station, to a selected one of the small object counting stations based on data stored in the respective container transport pallet RFID tag, from the selected small object counting station to the capping station, and from the capping station to the offloading station, and then transport the empty container transport pallets back to the small object container marking and loading station.

In various yet other embodiments, an exemplary method for packaging small objects is provided that includes singulating a plurality of small object containers, marking each singulated small object container with at least one information label, and loading each marked small object container into a respective one of a plurality of container transport pallets utilizing a small object container marking and loading station of a small object packaging system. The method additionally includes depositing a selected amount of small objects into each marked small object container based on data provided by the respective information label utilizing a small object counter of at least one small object counting station of the small object packaging system. The method further includes singulating a plurality of container caps and securing each singulated cap onto a respective marked small object container after the selected amount of small objects have been deposited therein utilizing a capping station of the small object packaging system. Furthermore, the method includes removing each capped small object container from the respective container transport pallet and placing each removed small object container into a container packing case using an offloading station of the small object packaging system. Still further, the method includes transporting the loaded container transport pallets from the small object container marking and loading station to the at least one small object counting station, to the capping station and to the offloading station, and then transporting the empty container transport pallets back to the small object container marking and loading station utilizing a main hub conveyor of the small object packaging system.

Further areas of applicability of the present teachings will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present teachings.

DRAWINGS

The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present teachings in any way.

FIG. 1 is an isometric view of an automated small object packaging system, in accordance with various embodiments of the present disclosure.

FIG. 1A is an isometric view of a main hub conveyor assembly of the small object packaging system shown in FIG. 1, in accordance with various embodiments of the present disclosure.

FIG. 2 is an isometric view of a small object container nested within a container transport pallet of the small object packaging system shown in FIG. 1, in accordance with various embodiments of the present disclosure.

FIG. 3 is an isometric view of a small object container marking and loading station of the small object packaging system shown in FIG. 1, in accordance with various embodiments of the present disclosure.

FIG. 3A is a side view of a marking and loading assembly of the small object container marking and loading station shown in FIG. 3, in accordance with various embodiments of the present disclosure.

FIG. 4 is an isometric view of a counting station of the small object packaging system shown in FIG. 1, in accordance with various embodiments of the present disclosure.

FIG. 4A is a side view of the counting station shown in FIG. 4, in accordance with various embodiments of the present disclosure.

FIG. 5 is an isometric view of a capping station of the small object packaging system shown in FIG. 1, in accordance with various embodiments of the present disclosure.

FIG. 5A is a side view of the capping station shown in FIG. 5, in accordance with various embodiments of the present disclosure.

FIG. 6 is an isometric view of an offloading station of the small object packaging system shown in FIG. 1, in accordance with various embodiments of the present disclosure.

FIG. 6A is an overhead view of the offloading station shown in FIG. 6, in accordance with various embodiments of the present disclosure.

FIG. 6B is a front view of the offloading station shown in FIG. 6, in accordance with various embodiments of the present disclosure.

FIG. 7 is a block diagram of a central control system of the automated small object packaging system shown in FIG. 1, in accordance with various embodiments of the present disclosure.

Corresponding reference numerals indicate corresponding parts throughout the several views of drawings.

DETAILED DESCRIPTION

The following description is merely exemplary in nature and is in no way intended to limit the present teachings, application, or uses. Throughout this specification, like reference numerals will be used to refer to like elements.

Referring to FIG. 1, an automated small object packaging system 10 is provided for separating selected amounts of small object from bulk quantities of various types of small objects, depositing the selected amounts into one or more containers, capping the containers and placing the capped containers into selected packing cases. The system 10 includes a main hub conveyor assembly 14, a small object container marking and loading station 18 operatively connected to the main hub conveyor assembly 14, one or more small object counting stations 22 operatively connected to the main hub conveyor assembly 14, at least one capping station 26 operatively connected to the main hub conveyor assembly 14, at least one offloading station 30 operatively connected to the main hub conveyor assembly 14, and a computer based central control system 32. The control system 32 is operable to directly or indirectly control and coordinate the automated and cooperative functions and operations of the main hub conveyor assembly 14, the small object container marking and loading station 18, the one or more small object counting stations 22, the at least one capping station 26, and the at least one offloading station 30.

Generally, the small object container marking and loading station 14 is structured and operable to singulate a plurality of small object containers 34 (shown in FIG. 2) mark each singulated small object container 34 with at least one information label 38 (shown in FIG. 2), and load each marked small object container 34 into a respective one of a plurality of container transport pallets 42 (shown in FIG. 2). Each small object counting station 22 is structured and operable to deposit a selected amount of small objects into each marked small object container 34 based on small object profile information and data provided by the respective information label 38. The capping station 26 is structured and operable to singulate a plurality of container caps 46 (shown in FIG. 2) and secure each singulated cap 46 onto a respective marked small object container 34 after the selected amount of small objects have been deposited therein. Each offloading station 30 is structured and operable to remove the capped small object containers 34 from the respective container transport pallet 42 and place each removed small object container 34 into a container packing case 50 (best shown in FIG. 6). And, the main hub conveyor assembly 14 is structured and operable to transport the loaded container transport pallets 42 from the small object container marking and loading station 18, to a selected one of the one or more small object counting stations 22, to the capping station 26 and to a selected one of the offloading stations 30, and then transport the empty container transport pallets 42 back to the small object container marking and loading station 18.

Referring now to FIGS. 1A, 2 and 3, in various embodiments, the small object container marking and loading station 18 includes a container singulator 54 and a marking and loading assembly 58 operatively connected to the container singulator 54. The container singulator 54 is structured and operable to receive a plurality of randomly oriented small object containers 34, singulate the small object containers 34, orient the singulated small object containers 34 in a desired orientation, and dispense the oriented small object containers 34 into a container transfer chute 62. For example, in various embodiments, the container singulator 54 can comprise a vibratory bowl feeder having a center bowl 66 disposed substantially in the center of a spiraled outer deck 70. The center bowl 66 is structured to receive and retain a plurality of the small object containers 34. The vibratory bowl feeder 54 further includes a motor (not shown) operable to vibrate the center bowl 66 and outer deck 70 such that the containers 34 are vibrated out of the center bowl 66 and move along the spiraled outer deck around center bowl 54.

As each of the containers 34 travel along the outer deck 70 a plurality of air jets 74 and singulating panels 78 singulate the containers 34 and orient them in a desired orientation. As used herein, the term ‘singulate’ means to automatically, e.g., robotically, sequentially separate objects one-at-a-time from a plurality of objects. The plurality of objects can include any number of objects greater than one. That is, the plurality of objects can include any number of objects from several or numerous objects, i.e., more than a single object, to a large volume of objects, i.e., a bulk quantity of the objects.

More particularly, the singulating panels 78 and air jets 74 separate each container 34 from the plurality of containers 34, orient them in a desired position, e.g., having a bottom of each container 34 oriented fore as the containers 34 travel around the center bowl 66, and feed them single-file into the container transfer chute 62. Each air jet 74 injects a stream of air into the path of the containers 34 as they move along the outer periphery of the outer deck 70. If the bottom of a particular container 34 is not the leading side of the respective container 34 as it travels past a particular air jet 74, the respective stream of air will rotate, or flip, the container 34 such that bottom of the respective container 34 becomes the leading side. Each singulating panel 78 is mounted to a bottom surface of the outer deck 70 in such a manner so as to define a continuously narrowing pathway for the travel of the containers 34 as the containers 34 move around the outer deck 70.

That is, each singulating panel 78 continuously restricts, or narrows, the distance between the respective singulating panel 78 and a sidewall 82 of the outer deck 70 such that the distance between a respective singulating panel 78 and the outer deck sidewall 82 near an ingress end 62A of the transfer chute 82 is only slightly larger than the width of a single container 34. Therefore, as containers 34 move around the outer deck 70 towards the container transfer chute 62, the singulating panels 78 progressively limit the number of containers 34 that can travel abreast of each other as they travel along the outer deck 70. Eventually, the singulating panels 78 force the containers 34 against the sidewall 82 such that, as the containers 34 approach the ingress end 62A of the transfer chute 62, the containers 34 are forced to travel single-file along the outer deck 70 between the respective singulating panel 78 and the sidewall 82, thereby feeding the containers 34 single-file into the transfer chute ingress end 62A.

Once the containers 34 enter the transfer chute 62, they travel along the transfer chute 62, via a conveyor belt, vibration, air or otherwise, to an egress end 62B of the transfer chute 62. The containers 34 are then selectively dispensed, i.e., dispensed one-at-a-time at selected intervals, onto a conveyor deck 86 of the marking and loading assembly 58. Once a container 34 is dispensed onto the conveyor deck 86, the respective container 34 is transported, via a conveyor belt, vibration, air or otherwise, along a length of the conveyor deck 86, whereby each container 34 has at least one container information label 38 disposed thereon.

For example, in various embodiments, once a container 34 is dispensed onto the conveyor deck 86, the respective container 34 is oriented in a first orientation, via any suitable orienting means, mechanism or system. For example, in various embodiments, the respective container 34 is oriented such that longitudinal side of the container 34 is oriented forward as the respective container 34 travels along the length of the conveyor deck 86. The respective container 34 is then transported along the conveyor deck 86 to a first marking zone adjacent a first marking assembly 90 where the respective container 34 has a first container information label 38A disposed on a first side of the respective container 34, e.g., a bottom side of the container 34.

Each first container information label 38A provides small object profile information and data regarding the small objects that are to be deposited within the respective container 34 and/or information regarding the respective container 34 once it is filled. For example, in various embodiments, the profile information and data can provide pertinent, statistical information such as the particular type, history, quantity of small objects that are to be deposited the respective container 34, and a future destination or site location of the each respective filled container 34.

The first marking assembly 90 can be structured and operable in any manner suitable to dispose the first container information label 38A on the first side of each container 34. For example, in various embodiments, the first marking assembly 90 can includes a retention mechanism structured and operable to temporarily retain, or hold, each container 34 at the first marking zone, and an inkjet printer structured and operable to print the first container information label 38A on the first side of each container 34 while each respective container 34 is being retained by the retention device. Additionally, the first container information label 38A can be any label or marking printed on or adhered to the container 34 that provides the respective profile information and data, i.e., pertinent information and data regarding the particular type, history, quantity of small objects that are to be deposited within the respective container 34, and/or any other pertinent information. For example, in various embodiments, each first container information label 38A comprises data matrix barcode and/or human readable text that provide the pertinent information.

The profile information to be included in the first container information label 38A is retrieved from the control system 32, i.e., from a database 94 (shown in FIG. 7) of the control system 32, on demand, a respective container 34 is positioned at the first marking zone. That is, as the respective container 34 is being positioned at the first marking zone, a control subsystem 98 of the container marking and loading station 18 requests the profile information and data to be included in the respective first container information label 38A from the control system 32. The control system 32 then accesses a particular look-up table or spreadsheet stored in the database 94 and returns the profile information and data to be included in the respective first container information label 38A.

More particularly, a plurality of look-up tables and/or spreadsheets are stored in the central control system database 94, wherein each look-up table and/or spreadsheet comprises data delineating the requirements of a particular small object packaging project, e.g., the number of containers 34 required for the particular project, the type, characteristics and amount (i.e., number or volume) of small objects to be deposited in each of the containers 34, a destination or site location of the each respective filled container 34, etc. The small object packaging system 10 further includes an operator control station 102 communicatively connected to the control system 32. Utilizing the operator control station 102, an operator can input requests to initiate a particular small object packaging project, and also enter data and/or information setting parameters and/or limits for the requested small object packaging project.

Hence, once an operator inputs a small object packaging project request, and sets any desired parameters and/or limits, operation of the small object packaging system 10 begins. At which point, containers 34 are singulated and dispensed into the container marking and loading assembly 58, as described above. Then, as each respective container 34 is positioned at the first marking zone, the marking and loading station control subsystem 98 requests and receives from the control system 32 the information and data stored in the requested packaging project look-up table and/or spreadsheet that provides the profile information and data to be included in the first container information label 38A to be disposed on the particular container 34.

In various embodiments, the marking and loading assembly 58 additionally includes a first container information label verification assembly 104 that is structured and operable to verify that the first container information label 38A disposed on each respective container 34 is valid, i.e., legible and correct. More specifically, after a container 34 is marked with the first container information label 38A, the respective first container information label 38A is read or scanned by the first container information label verification assembly 104 to ensure that each respective first container information label 38A is valid before each respective container is allowed to be further processed by the small object packaging system 10, as described below. If the first container information label verification assembly 104 determines that a particular first container information label 38A is invalid, i.e., incorrect or not legible, a first rejection assembly 106 discards the respective container 34, i.e., removes the respective container 34 from the conveyor deck 86. If a first container information label 38A is found to be invalid and is discarded, a subsequent container 34 is marked with a first container information label 38A containing the same information and data as that disposed on the discarded container 34 and the respective container 34 is verified, via the first container information label verification assembly 104. This process is repeated until a first container information label 38A containing the subject information and data is found to be valid.

The first container information label verification assembly 104 can include any one or more devices, mechanisms, systems or apparatuses suitably structured and operable to verify each first container information label 38A. For example, in various embodiments, the first container information label verification assembly 104 comprises an imaging device, e.g., a data matrix barcode reader and/or digital imaging device, communicatively coupled to the control system 32. The imaging device is operable to acquire image data of the respective first container information label 38A. The acquired image data is communicated to the control system 32 where it is determined whether the acquired image data is legible, and if so, whether the acquired image data provides the correct information and data, i.e., the information and data intended to be provided by the respective first container information label 38A.

Additionally, in various embodiments, after the first container information label 38A has been disposed on the first side of a container 34, the respective container 34 is reoriented to a second orientation, via any suitable orienting means, mechanism or system. For example, in various embodiments, the respective container 34 is rotated 90° such that the bottom side of the container 34 is oriented forward as the respective container 34 travels along the length of the conveyor deck 86. The container 34 is then transported along the conveyor deck 86 to a second marking zone adjacent a second marking assembly 110 where the respective container 34 has a second container information label 38B disposed on a second side of the respective container 34, e.g., the longitudinal side of the container 34. The second container information label 38B can be any label or marking printed on or adhered to the container 34 that provides profile information or data regarding the small objects that are to be deposited within the respective container 34 and/or information regarding the respective container 34 once it is filled. For example, in various embodiments, the second container information label 38B can contain a data matrix barcode and/or human readable text that provide substantially the same information provided by the first container information label 38A.

In the various embodiments wherein the marking and loading assembly 58 includes the second marking assembly 110, the marking and loading assembly 58 can further include a second container information label verification assembly 114 that is structured and operable to verify that the second container information label 38B disposed on each respective container 34 is valid, i.e., legible and correct. More specifically, after a container 34 is marked with the second container information label 38B, the respective second container information label 38B is read or scanned by the second container information label verification assembly 114 to ensure that each respective second container information label 38B is valid before each respective container is allowed to be further processed by the small object packaging system 10, as described below. If the second container information label verification assembly 114 determines that a particular second container information label 38B is invalid, i.e., incorrect or not legible, a second rejection assembly 118 discards the respective container 34, i.e., removes the respective container 34 from the conveyor deck 86. If a second container information label 38B is found to be invalid and is discarded, a subsequent container 34 is marked with a first and second container information label 38A and 38B containing the same information and data as that disposed on the discarded container 34 and the respective container 34 is verified, via the first and second container information label verification assemblies 104 and 114. This process is repeated until first and second container information labels 38A and 38B containing the subject information and data are found to be valid.

The second container information label verification assembly 114 can include any one or more devices, mechanisms, systems or apparatuses suitably structured and operable to verify each second container information label 38B. For example, in various embodiments, the second container information label verification assembly 114 comprises an imaging camera, e.g., a data matrix barcode reader and/or digital imaging device, communicatively coupled to the control system 32. The imaging device is operable to acquire image data of the respective second container information label 38B. The acquired image data is communicated to the control system 32 where it is determined whether the acquired image data is legible, and if so, whether the acquired image data provides the correct information and data, i.e., the information and data intended to be provided by the respective second container information label 38B.

Now referring to FIGS. 1, 1A, 2, 3 and 3A, once a respective container 34 has been marked with at least one information label 38, i.e., a first information label 38A and/or a second information label 38B, the marked container 34 is transported along the conveyor deck 86 to a loading assembly 122. The loading assembly is structured and operable to transfer each marked container 34 from the conveyor deck 86 into a respective container transport pallet 42 positioned beneath the loading assembly 122 on a conveyor track 126 of the main hub conveyor assembly 14. More particularly, prior to, or substantially simultaneous with, a marked container 34 being transported to the loading assembly 122, an empty transport pallet 42 is conveyed along the main hub conveyor track 126 to a container loading pallet locator 130 (best shown in FIG. 1A) of the main hub conveyor assembly 14. The pallet locator 130 is structured and operable, as controlled by the control system 32, to grasp and retain the respective transport pallet 42 beneath the loading assembly 122.

More particularly, when a transport pallet 42 is transported to a position under the loading assembly 122, the pallet locator 130 stops the transport pallet 42 and grasps the transport pallet 42 such that the transport pallet 42 is accurately located at a loading zone located beneath a loading receptacle 134 of the loading assembly 122. The pallet locator 130 then slightly lifts the respective transport pallet 42 off the main hub conveyor track 126. The loading assembly additionally includes a linear actuator 138 that is structured and operable, as controlled by the control system 32, to bidirectionally move a seating ram 142 in the Y⁺ and Y⁻ directions. Once a container 34 has been properly marked with at least one container information label 38, the container 34 is transported to the loading receptacle 134 where each respective container 34 is positioned to be loaded in a respective transport pallet 42 by the seating ram 142.

More specifically, upon completion of the marking process, each marked container 34 is oriented such that the bottom side is oriented forward as the respective container 34 travels along the conveyor deck 86. Each container 34 is then is transported to a distal end of the conveyor deck 86 where the loading receptacle 134 is located such that each respective container 34 will fall, or be placed, ‘bottom side down’, ‘open top side up’ into the loading receptacle 134. The loading receptacle 134 includes a first half 134A connected to a first actuator 144A and a second half 134B connected to a second actuator 144B. The first and second linear actuators 144A and 144B are operable, as controlled by the control system 32, to bidirectionally move the respective loading receptacle first and second halves 134A and 134B in the X⁺ and X⁻ directions.

When the first and second actuators 144A and 144B are in a fully extended position, i.e., a Closed position, the respective loading receptacle first and second halves 134A and 134B form a Closed loading receptacle 134. The Closed loading receptacle 134 is generally structured as a square, or rectangular, funnel having angled interior sides and a distal end opening that is substantially same size and shape as a lateral cross-section of the container 34. Hence, when a marked container 34 falls into the Closed loading receptacle 134, the respective container 34 will slide down the sides of the loading receptacle 134 and stop, due to friction, with the bottom end of the container at, or near, the open distal end of the loading receptacle 134. In various implementations, the loading assembly 122 can include a plurality of loading receptacles and seating rams 142, whereby more than one marked container 34 can be positioned in preparation for loading into respective transport pallets 42.

To load a marked container 34 into a respective transport pallet 42 positioned beneath the loading receptacle 134, once a container is positioned within the Closed loading receptacle 134, the linear actuator 138, as controlled by the control system 32, lowers the seating ram 142 in the Y⁻ direction such that a seating head 146, connected to an distal end of the seating ram 142, pushes the container 34 partially out of the distal end opening of the loading receptacle 134 and into a container nest 150 of the respective transport pallet 42. The container nest 150 is generally structured as a square or rectangular cup having angled interior sides such that as the container 34 is pushed into the container nest 154, the angled interior sides center the bottom end of the container 34 within the container nest 150. Additionally, as the bottom end of the container 34 is pushed into the bottom of the container nest 150, the angled interior sides slightly compress and grasp, i.e., positively secure, the bottom portion of the respective container 34 via friction.

Once the removed container 34 is seated, i.e., positively secured, within respective transport pallet container nest 150, the first and second linear actuator 144A and 144B retract to Open the loading receptacle 134. In the Open position the loading receptacle first and second halves 134A and 134B are moved away from the respective container 34 such that the respective transport pallet 42 along with the seated container 34 can be moved along the main hub conveyor track 126 toward the one or more counting stations 22. Subsequently, the first and second linear actuator 144A and 144B extend to return the loading receptacle first and second halves 134A and 134B to the Closed position to receive a subsequent marked container 34.

Referring now to FIGS. 1A and 2, to link each marked container with the respective transport pallet 42, each transport pallet 42 includes a pallet identification tag 154 disposed thereon. Each pallet identification tag 154 is programmed with, or comprises, pallet identification data that is linked, tied, correlated or associated with the marked container 34 seated with the container nest 150 of the respective transport pallet 42 within the database of the control system 32. More particularly, each pallet identification tag 154 includes, or is programmed with, a unique identifier, i.e., information or data, that is unique to and identifies the respective transport pallet 42. Accordingly, each transport pallet 42 is linked, tied, correlated or associated with the respective container 34 disposed therein, and more particularly with the profile information and data provided by the at least one container information label 38 of the respective container 34.

Additionally, the small object packaging system 10 includes a plurality of pallet identification tag reader/writers 158 disposed at various locations along the main hub conveyor assembly 14. Particularly, a marking and loading station pallet identification tag reader/writer 158P is located at or near the pallet locator 130 such that as a marked container 34 is seated into the container nest 150 of a transport pallet 42, the identification tag 154 of the transport pallet 42 is programmed with a unique identifier, or has a preprogrammed unique identifier read, by the marking and loading station tag reader/writer 158P to identify the particular transport pallet 42. The particular transport pallet unique identifier is communicated to the control system 32 where the pallet unique identifier is linked, tied, correlated or associated with the respective container 34, and more particularly, with the profile information and data provided by the at least one container information label 38 of the respective container 34.

Therefore, as each transport pallet 42 and respective container 34 are transported along the conveyor track 126 of main hub conveyor assembly 14 the various pallet identification tag reader/writers 158 read the respective identification tags 154 such that location and status of each container/pallet 34/42 within the small object packaging system 10 is known by the control system 32 throughout the small object packaging process of each respective container/pallet 34/42, as described herein. Moreover, the linking of the particular transport pallet unique identifier with the profile information and data associated with the container information label(s) 38 of the respective container 34 is used to guide the flow/travel path of each respective transport pallet 42 and container 34 within the small object packaging system 10 based on the particular profile information and data associated with the information label(s) 38 disposed on the respective container 34.

The pallet identification tags 154 can be any device or item suitable for storing and providing unique identification information for each respective transport pallet 42. For example, in various embodiments, each pallet identification tag 154 can comprise a radio frequency identification (RFID) tag programmable to have the unique identifier, i.e., information and/or data, electronically stored therein. In such instances, the pallet identification tag reader/writers 158 comprise RFID reader/writers operable to write and read the unique identifier of each transport pallet 42 at the various selected points throughout the small object packaging process. In various other embodiments, any other suitable machine-readable pallet identification tags 154 can be used, such as two-dimensional matrix codes or other machine-readable/writeable tags or devices in which the data can been written to and/or received from, via wireless communication, such as optical signals, e.g., infrared signals, or magnetic fields.

Once a marked container 34 has been loaded into a transport pallet 42, the respective pallet identification tag 154 has been programmed with a unique identifier, or has had a preprogrammed unique identifier read therefrom, and the pallet unique identifier has been linked to the profile information and data associated with the respective container information label(s) 38, the respective container/pallet 34/42 is released from the pallet locator 130 and transported, via the main hub conveyor track 126, to a particular one of the small object counting station(s) 22. Although, in various embodiments, the small object packaging system 10 can include only a single counting station 22, for exemplary purposes, hereafter, the small object packaging system 10 will be described as including a plurality, i.e., exemplarily three, small object counting stations 22. As illustrated in FIG. 1, in such embodiments, the three counting stations 22 are spaced apart and sequentially connected adjacent each other to the main hub conveyor assembly 14. The three counting stations 22 will be referred to herein as the first counting station 22A, the second counting station 22B and the third counting station 22C. Each of the first, second and third counting stations 22A, 22B and 22C are substantially identical in structure and operation. Hence, the counting station illustrated in FIGS. 4 and 4A, and the corresponding description herein, exemplifies the structure and operability of each counting station 22 of the small object packaging system 10.

Referring now to FIGS. 1, 1 A, 4 and 4A, as a container/pallet 34/42 travels along the main hub conveyor track 126 toward the first counting station 22A the container/pallet 34/42 will pass a first counting station tag reader/writer 158A. As the container/pallet 34/42 passes the first counting station tag reader/writer 158A, the pallet unique identifier is acquired from respective pallet identification tag 154 and communicated to the control system 32 by the first counting station tag reader/writer 158A. Then, the control system 32 accesses the profile information and data linked to the particular pallet unique identifier to determine whether the container/pallet 34/42 is to be routed to first counting station 22A.

In various embodiments, each of the counting stations 22 can be configured to deposit the same small objects, i.e., small objects of the same type, quality, genetic characteristics, etc., into the containers 34 routed to the respective counting stations 22. Or, in other embodiments, at least two of the counting stations 22 can be configured to deposit the different small objects, i.e., small objects of different types, and/or having different qualities, genetic characteristics, etc., into the containers 34 routed to the respective counting stations 22.

If, based on the respective profile information and data, the control system 32 determines that the container/pallet 34/42 is not to be routed to the first counting station 22A, a diverter gate 162 of the first counting station 22A, as controlled by the control system 32, will be placed in a Closed position, as shown in FIG. 4. Accordingly, the container/pallet 34/42 will travel past the first counting station 22A pass a second counting station tag reader/writer 158B where the pallet unique identifier is again acquired from respective pallet identification tag 154 and communicated to the control system 32. Then, based on the respective profile information and data, the control system 32 determines whether the container/pallet 34/42 is to be routed to second counting station 22B.

If it is determined that the container/pallet 34/42 is not to be routed to the second counting station 22B, a diverter gate 162 of the second counting station 22B, as controlled by the control system 32, will be placed in a Closed position, as shown in FIG. 4. Accordingly, the respective container/pallet 34/42 will travel past the first counting station 22A and pass a second counting station tag reader/writer 158B where the pallet unique identifier is again acquired from respective pallet identification tag 154 and communicated to the control system 32. Then, based on the respective profile information and data, the control system 32 determines whether the respective container/pallet 34/42 is to be routed to second counting station 22A.

If it is determined that the container/pallet 34/42 is not to be routed to the second counting station 22B, a diverter gate 162 of the second counting station 22B, as controlled by the control system 32, will be placed in a Closed position, as shown in FIG. 4. Accordingly, the respective container/pallet 34/42 will travel past the second counting station 22B and pass a third counting station tag reader/writer 158C where the pallet unique identifier is again acquired from respective pallet identification tag 154 and communicated to the control system 32. Then, based on the respective profile information and data, the control system 32 determines whether the respective container/pallet 34/42 is to be routed to third counting station 22B.

Once it is determined that a container/pallet 34/42 is to be routed to particular counting station 22, respective diverter gate 162 of the counting station 22 will be placed in an Open position where by the diverter gate is moved to extend over the main hub conveyor track 126 such that the container/pallet 34/42 is diverted onto a counting station conveyor track 166. The container/pallet 34/42 is then transported to a counting depot pallet locator 170 located beneath a small object counter 174 where the container/pallet 34/42 is stopped and a particular amount of small objects are deposited into the respective container 34. The amount of small objects deposited is determined and controlled by the control system 32 based on the respective profile information and data of the respective container 34. The particular amount of small objects can be a particular volume of small objects or a particular number of small objects.

More specifically, when a container/pallet 34/42 is transported to a position under the small object counter 174, the depot pallet locator 170 stops the container/pallet 34/42 and grasps the respective transport pallet 42 such that the respective container 34 is accurately located beneath an output port 178 of the counter 174. The depot pallet locator 170 then slightly lifts the respective container/pallet 34/42 off the counting station conveyor track 166, whereafter the amount of small objects specified by the respective container profile information/data are deposited into the respective container 34. More particularly, in various embodiments, the counting station 22 includes a pallet identification tag reader 182 that is substantially identical in structure and operation as the main hub pallet identification tag readers 158. The counting station pallet identification tag reader 182 is located such that the pallet identification tag 154 of the container/pallet 34/42 being transported along the counting station conveyor track 166 is read prior to the container/pallet 34/42 reaching the depot pallet locator 170. Hence, prior to, or substantially simultaneous with, the respective container 34 being located beneath the counter output port 178, the unique identifier of the respective transport pallet 42 is used to access the respective container 34 profile information/data to specify the amount of small objects to be deposited into the respective container 34.

Generally, the counter 174 is structured to receive a plurality, or bulk quantity, of small objects in a hopper 184 of the counter 174. Additionally, as controlled by the control system 32, the counter 174 operates to singulate the plurality, or bulk quantity, of small objects and count and dispense the specified amount of small objects dictated by the respective container profile information and data. Therefore, a container/pallet 34/42 that is diverted to a particular counting station 22 will be transported along the respective counting station conveyor track 166, past the respective counting station pallet identification tag reader 182 and be positioned beneath the respective counter output port 178 by the respective depot pallet locator 170. As the container/pallet 34/42 passes the respective counting station pallet identification tag reader 182, the respective pallet identification tag 154 is read and the respective pallet unique identifier is communicated to the control system 32. Then, based on the pallet unique identifier, the control system 32 determines the respective container profile information/data, which includes the specified amount of small objects to be deposited into the respective container 34. Subsequently, the specified amount of small objects to be deposited into the respective container 34 is communicated to the respective counter 174. The respective counter 174 then singulates, counts and dispenses the specified amount of small objects in the respective container 34.

The counter 174, generally described herein, is substantially similar in structure and operation to the high speed counter described in co-pending PCT patent application serial number PCT/US09/48992, filed Jun. 29, 2009 and titled High Speed Counter, which claims priority to U.S. Provisional Application Ser. No. 61/077,766, filed Jul. 2, 2008, each of which is incorporated by reference herein in their entirety.

In various embodiments, each counting station 22 additionally includes an accumulator/diverter device 186 disposed beneath the respective counter output port 178 such that the respective counter 174 dispenses the singulated and counted small objects into the accumulator/diverter device 186. Each accumulator/diverter device 186 is structured and operable to accumulate, i.e., aggregate, and retain the singulated small objects counted and dispensed by the respective counter 174, then dispense the accumulated small objects into the waiting container 34, via an output port 190. More particularly, each accumulator/diverter device 186 comprises a plurality of interior accumulating chambers (not shown) and a diverter mechanism (not shown). The diverter mechanism is structured and operable to divert, i.e., direct, small objects singulated and counted by respective counter 174 into one of the accumulating chambers.

More specifically, as the respective counter 174 singulates, counts and dispenses a specified amount of small objects based on the profile information/data of a particular container 34 that has passed the pallet identification tag reader of the respective counting station 22, the diverter directs the dispensed small objects to a first one of the accumulating chambers. Then, while retaining the small objects in the first accumulating chamber, the diverter, as controlled by the control system 32, is moved to direct singulated, counted and dispensed small objects to be deposited in another container 34 that has passed the pallet identification tag reader of the respective counting station 22 into a second one of the accumulating chambers. Each accumulator further includes a flow control device (not shown) that is structured and operable, as controlled by the control system 32, to control the release of the accumulated small objects from each of the accumulating chambers.

Hence, once a first container/pallet 34/42 passes the pallet identification tag reader 182 of a particular counting station 22, the respective counter 174 will singulate, count and dispense the designated amount of small objects for the respective first container 34 into the respective accumulator/diverter device 186. As described above, the accumulator/diverter device 186 will accumulate the small objects in a first one of the accumulating chambers. The first container/pallet 34/42 will then be transported to the respective depot pallet locator 170. During this time, a second container/pallet 34/42 can pass the identification tag reader 182 and the respective counter 174 can singulate, count and dispense the designated amount of small objects for the respective second container 34 into the respective accumulator/diverter device 186, which accumulates the small objects in a second one of the accumulating chambers. Substantially simultaneously with singulating, counting and accumulating the specified amount of small objects in the second accumulating chamber, the flow control device of the accumulator can release of the accumulated small objects from the first accumulating chamber, thereby depositing the small objects in the first container 34.

The depot pallet locator 170 can the release the first container/pallet 34/42 and then position the second container/pallet 34/42 beneath the accumulator output port 190. Then, substantially simultaneously with the small objects being released from the second accumulator chamber and deposited into the second container 34, a third group of small objects for a third container 34 can be singulated, counted and accumulated the first accumulating chamber, and so on.

Once the stipulated amount of small objects has been deposited in a container 34, the respective container/pallet 34/42 is released by the depot pallet locator 170 and transported along the respective counting station conveyor track 166 toward the respective diverter gate 162. As filled container/pallet 34/42 approaches the diverter gate 162, the control system 32 moves the diverter gate 162 to the Closed position such that the filled container/pallet 34/42 is directed back onto the main hub conveyor track 126, whereby the filled container/pallet 34/42 is transported to the capping station 26.

As described above, the specified amount of small objects to be deposited in each respective container 34 can be a particular volume of small objects or a particular number of small objects. In the implementations where a particular volume of small objects are to be deposited, one or more optical sensors (not shown) can be disposed adjacent the counting depot 170 or, in embodiments including the accumulator/diverter device 186, within each of the interior accumulating chambers of the accumulator/diverter device 186. The optical sensor(s), as controlled by the control system 32, would determine when the particular volume of small objects, as specified by the small object profile corresponding the respective container 34, has been deposited into the respective container 34, or the respective accumulator chamber. Once the specified volume of small objects has been deposited into the respective container 34 or accumulator chamber, the control system 32 ceases operation of the counter 174, until a subsequent container 34 has been positioned beneath the counter output port 178, or the accumulator diverter mechanism has been moved to direct subsequent small objects into a second interior accumulating chamber of the accumulator/diverter device 186. In such implementations, the counter 174 can count the number of small objects dispensed to comprise the specified volume, and communicate that number to the central control system where the particular number would be stored in the look-up tables and/or spreadsheet and become part of the respective container small object profile.

In the implementations where a particular number of small objects are to be deposited in each container 34, the counter dispenses the specified number of small objects into the respective container 34 or, in embodiments including the accumulator/diverter device 186, into one of the accumulator interior accumulating chambers. Once the specified number of small objects has been deposited into the respective container 34 or accumulator chamber, the control system 32 ceases operation of the counter 174, until a subsequent container 34 has been positioned beneath the counter output port 178, or the accumulator diverter mechanism has been moved to direct subsequent small objects into a second interior accumulating chamber of the accumulator/diverter device 186.

In various embodiments, the each counting station 22 can include a container tamping linear actuator 194 and a tamping pallet locator 198. In such embodiments, the tamping pallet locator 198 is located before the depot pallet locator in the travel path of the container/pallets 34/42 along the counting station conveyor track 166. The tamping pallet locator 198 is structured and operable to stop the respective container/pallet 34/42 such that the respective container 34 is accurately located beneath a tamping plate 202 of the tamping linear actuator 194. The tamping linear actuator 194 is structured and operable, as controlled by the controls system 32, to bidirectionally move tamping plate 202 in the Y⁺ and Y⁻ directions. More particularly, as a container/pallet 34/42 is transported along the counting station conveyor track 166 toward the counter 174, the container/pallet 34/42 is stopped, grasped and lifted by the tamping pallet locator 198. The tamping linear actuator 194 then lowers the tamping plate 202 in the Y⁻ direction such that the tamping plate contacts the top of the respective container 34 and slightly pushes down, in the Y⁻ direction, on the respective container 34, thereby ensuring that the respective container 34 is properly seated in the container nest 150 of the respective pallet 42. Subsequently, the tamping linear actuator 194 then raises the tamping plate 202 in the Y⁺ direction, the tamping pallet locator 198 releases the container/pallet 34/42 and the container/pallet 34/42 is transported to the counting depot pallet locator 170 to have the specified amount of seeds deposited into the respective container 34, as described above.

Referring now to FIGS. 5 and 5A, once the specified amount of small objects have been deposited into a container 34 and the respective container/pallet 34/42 has been transported back onto the main hub conveyer 126, the container/pallet 34/42 is transported to the capping station 26. More particularly, the container/pallet 34/42 is transported to a capping pallet locator 214, whereby the container/pallet 34/42 is stopped, grasped and lifted adjacent the capping station 26. The capping station 26 generally includes a container cap singulator 206 and a robotic capping assembly 210.

The cap singulator 206 is structured and operable to receive a plurality of randomly oriented containers caps 46, singulate the caps 46, orient the singulated caps 46 in a desired orientation, and dispense the oriented caps 46 into a cap transfer chute 218. For example, in various embodiments, the cap singulator 206 can comprise a vibratory bowl feeder having a center bowl 222 disposed substantially in the center of a spiraled outer deck 226. The center bowl 222 is structured to receive and retain a plurality of the container caps 46. The vibratory bowl feeder 206 further includes a motor (not shown) operable to vibrate the center bowl 222 and outer deck 226 such that the container caps 46 are vibrated out of the center bowl 222 and move along the spiraled outer deck 226 around center bowl 222. The vibratory bowl feeder 206 further includes at least one air jet 230 and at least one singulating panel 234. The vibratory bowl feeder 206 operates to singulate and properly orient the caps 46, i.e., container insert lip down and solid top up, then feed the singulated and oriented caps single-file into the cap transfer chute 218, in substantially the same manner as the vibratory bowl feeder operates to singulate and properly orient the container 34 then feed the singulated and oriented containers single-file into the container transfer chute 62, as described above.

Once the caps 46 enter the transfer chute 218, they travel along the transfer chute 218, via a conveyor belt, vibration, air or otherwise, to an staging receptacle 236 disposed at a distal end of the transfer chute 218. The caps 46 are then selectively removed, i.e., removed one-at-a-time at selected intervals, from an egress end 218B of the transfer chute 218 and placed on corresponding containers 34 by the robotic capping assembly 210.

More specifically, once the specified amount of small objects have been deposited into a container 34 and the respective container/pallet 34/42 has been transported back onto the main hub conveyer 126, the container/pallet 34/42 is transported to the capping pallet locator 214. The capping pallet locator 214 stops, grasps and lifts the container/pallet 34/42 adjacent the robotic capping assembly 210 such that the respective container 34 is positioned beneath a cap gripping head 238 of a capping head linear actuator 242 of the robotic capping assembly 210. The robotic capping assembly 210 additionally includes a boom arm linear stage 246 that includes a carriage 250 to which the capping head linear actuator 242 is mounted and a cap presentation linear actuator 254. The boom arm linear stage 246 is structured and operable, as controlled by the control system 32, to bidirectionally move the carriage 250 and capping head linear actuator 242 in the X⁺ and X⁻ directions. The capping head linear actuator 242 is structured and operable, as controlled by the control system 32, to bidirectionally move a cap gripping head 238 in the Y⁺ and Y⁻ directions.

Once a container 34 has been positioned beneath the cap gripping head 238, the cap presentation linear actuator 254, as controlled by the control system 32, raises a presentation pedestal 258 in the Y⁺ direction to lift a cap 46 resting in the staging receptacle 236 slightly out of the staging receptacle 236. Substantially simultaneously, the capping head linear actuator 242, as controlled by the control system 32 raises the cap gripping head 238 in the Y⁺ direction such that the cap gripping head 238 is at a level higher than cap 46. The boom arm linear stage 246, as controlled by the control system 32, then moves the carriage 250 and capping head linear actuator 242 along the boom arm 246 in the X⁺ direction until the cap gripping head 238 is positioned directly above the container 34 to be removed. The presentation pedestal 258 then raises the cap 46 in the Y⁺ direction until the cap gripping head 238 receives the cap 46.

The cap gripping head 238 is generally structured as a square, or rectangular, cup having angled interior sides such that as the cap gripping head 238 is lowered over the respective cap 46 the angled interior sides center the cap within the cap gripping head 238 as the cap 46 enters the cap gripping head 238. Then, as the cap 46 is pushed into the bottom of the cap gripping head 238, the angled interior sides slightly compress the edges of the cap 46 to grasp, i.e., positively secure, the cap 46 via friction.

The presentation pedestal 258 then lowers in the pedestal 258 then lowers in the Y⁻ direction until it is clear from the impending motion of the cap grippng head 238 by translation of the boom are linear stage 246.

The boom arm linear stage 246, then moves the carriage 250, capping head linear actuator 242 and removed cap 46 along the boom arm 246 in the X⁺ direction until the removed container cap 46 is positioned directly above the container 34 of the container/pallet 34/42 being retained by the capping pallet locator 214. The capping head linear actuator 242 then lowers the removed cap 46 in the Y⁻ direction until the removed cap 46 is secured on the respective container 34. Once the cap 46 is seated, i.e., positively secured, on the respective container 34, the capping head linear actuator 242 raises cap gripping head 238 to remove the cap gripping head 238 from the cap 46. In various embodiments, the frictional force between the cap 46 and the top of the container 34 is greater than the frictional force between the cap gripping head 238 and the edges of the cap 46. Therefore, as the cap gripping head 238 is raised, the cap 46 will remain seated on the container 34 as the cap gripping head 238 is removed from the edges of the cap 46. Alternatively, in various embodiments, the cap gripping head 238 can be structured to include mechanical gripping jaws that are operable, as controlled by the control system 32, to open and close to engage and disengage the jaws about the respective cap 46 to remove the respective cap 46 from the presentation pedestal and/or place the respective cap 46 on the respective container 34.

Referring now to FIG. 1A, in various embodiments, the small object packaging station 10 includes an auxiliary conveyor track 262 mounted along side the main hub conveyor track 126 between the capping station 26 and the offload station 30. The auxiliary conveyor 262 can be used to park loaded and capped container/pallets 34/42 while waiting to have the respective containers 34 offloaded at the offload station 30, as described below. To move selected container/pallets 34/42 between the main hub conveyor track 126 and the auxiliary conveyor track 262, the small object packaging station 10 includes a removal lift and transfer assembly 266 and a return lift and transfer assembly 270. More specifically, the removal lift and transfer assembly 266 is structured and operable to transfer selected loaded and capped container/pallets 34/42 from the main hub conveyor track 126 to the auxiliary conveyor track 262. Conversely, the return lift and transfer assembly 270 is structured and operable to transfer empty transport pallets 42 from the auxiliary conveyor track 262 to the main hub conveyor track 126.

The removal lift and transfer assembly 266 includes a container/pallet stop device 272, a removal lift bridge 274 mounted between the main hub and auxiliary conveyor tracks 126 and 262, and a linear actuator 278 mounted to a side of the main hub conveyor 126. The stop device 272 is structured and operable, as controlled by the control system 32, to stop selected loaded and capped container/pallets 34/42 adjacent the linear actuator 278. Once a selected loaded and capped container/pallet 34/42 is stopped by the stop device 272, the removal lift bridge 274, as controlled by the control system 32, is lowered from a Barrier position to a Bridge position, thereby exposing a gap in a side rail of the main hub conveyor track 126. When in the Barrier position, the removal lift bridge 274 is raised, filling the gap in the main hub conveyor track side rail, thereby providing a side rail for loaded and capped container/pallets 34/42 traveling past the stop device 272. When in the Bridge position, the removal lift bridge 274 is lowered, exposing the gap in the main hub conveyor track side rail and providing a bridge for the selected loaded and capped container/pallet 34/42 to be moved from the main hub conveyor track 126 to the auxiliary conveyor track 262.

Additionally, when the removal lift bridge 274 is lowered to the Bridge position, a gap in the side rail of the auxiliary conveyor track 262 is exposed in the same manner as the gap in the main hub conveyor track side rail. After a loaded and capped container/pallet 34/42 is stopped and the removal lift bridge 274 is lowered to the Bridge position, the removal linear actuator 278 is activated, as controlled by the control system 32, to extend a push bar 282, thereby pushing the loaded and capped container/pallet 34/42 from the main hub conveyor track, across the removal lift bridge 274 and onto the auxiliary conveyor track 262. Subsequently, the removal lift bridge 274 is raised to the Barrier position to provide the side rails for the main hub and auxiliary conveyor tracks 126 and 262.

Similarly, the return lift and transfer assembly 270 includes a container/pallet stop device 286, a return lift bridge 290 mounted between the main hub and auxiliary conveyor tracks 126 and 262, and a linear actuator 294 mounted to a side of the auxiliary hub conveyor 262. The stop device 286 is structured and operable, as controlled by the control system 32, to stop emptied pallets 42, i.e., pallets 42 that have been moved to the auxiliary conveyor track 262 and had the respective container 34 offloaded via the offload station 30, when the emptied pallets 42 are transported to a position adjacent the linear actuator 294.

Once an emptied pallet 42 is stopped by the stop device 286, the return lift bridge 290, as controlled by the control system 32, is lowered from a Barrier position to a Bridge position, thereby exposing a gap in a side rail of the auxiliary conveyor track 262. When in the Barrier position, the return lift bridge 290 is raised, filling the gap in the auxiliary conveyor track side rail, thereby providing a side rail for emptied pallets 42 traveling to the stop device 286. When in the Bridge position, the return lift bridge 290 is lowered, exposing the gap in the auxiliary conveyor track side rail and providing a bridge for the emptied pallets 42 to be moved from the auxiliary conveyor track 262 to the main hub conveyor track 126.

Additionally, when the return lift bridge 290 is lowered to the Bridge position, a gap in the side rail of the main hub conveyor track 126 is exposed in the same manner as the gap in the auxiliary conveyor track side rail. After an emptied pallet 42 is stopped and the return lift bridge 290 is lowered to the Bridge position, the return linear actuator 294 is activated, as controlled by the control system 32, to extend a push bar 298, thereby pushing the emptied pallet 42 from the auxiliary conveyor track 262, across the return lift bridge 290 and onto the main hub conveyor track 126. Subsequently, the return lift bridge 290 is raised to the Barrier position to provide the side rails for the auxiliary and main hub conveyor tracks 126 and 262. Once an emptied pallet 42 is moved back to the main hub conveyor track 126, the respective emptied pallet 42 can be queued to be reprocessed by the container marking and loading station 18, loaded with another marked container 34, as described above.

As described above, once a loaded container 34 has been capped at the capping station 26, the loaded container/pallet 34/42 can be moved to the auxiliary conveyor track 262 and transported to the offloading station 30 to have the respective loaded and capped container 34 removed from the respective pallet 42. Or, alternatively, the loaded and capped container/pallet 34/42 can remain on the main hub conveyor and transported to the offloading station 30 to have the respective loaded and capped container 34 removed from the respective pallet 42. More specifically, a loaded and capped container/pallet 34/42 remaining on the main hub conveyor track 126 will be transported to a main hub offload pallet locator 302 for offloading of the respective loaded and capped container 34. And, similarly, a loaded and capped container/pallet 34/42 that has been moved to the auxiliary conveyor track 262 will be transported to an auxiliary offload pallet locator 304 for offloading of the respective loaded and capped container 34.

Referring now to FIGS. 6 and 6A, once a loaded and capped container/pallet 34/42 has been moved to either the main hub offload pallet locator 302 or the auxiliary offload pallet locator 304, a Cartesian robotic offload assembly 308 removes the respective loaded and capped containers 34 and selectively places each offloaded loaded and capped container 34 in a container packing case 50. In various embodiments, as described herein, the Cartesian robotic offload assembly 308 removes the respective loaded and capped containers 34 and selectively places each offloaded loaded and capped container 34 in a selected one of a plurality of container packing cases 50.

The offloading station additionally includes a box transport assembly 316 that is structured and operable, as controlled by the control system 32, to convey the container packing cases 50 to and from a loading position at which the offloaded loaded and capped containers 34 are placed into the selected container packing cases 50 boxes. Particularly, the box transport system 316 includes a plurality of box conveyor linear stages 320 that are each structured and operable, as controlled by the control system 32, to convey container packing cases 50 from a box handling end 320A of each respective box conveyor linear stage 320 to a container loading end 320B of each respective box conveyor linear stage 320. At the handling ends 320A, empty container packing cases 50 can be placed onto, and loaded container packing cases 50 can be removed from a carriage 324 of the respective box conveyor linear stage 320. Each container packing case 50 is partitioned to include a plurality of cells 328 sized to receive and retain a single loaded and capped container 34. For example, in various embodiments, each container packing case 50 can include forty-eight cells 328 arranged in a 4×12 array.

Accordingly, an operator can place an empty container packing case 50 on each of the linear stage carriages 324 whereafter the respective box conveyor linear stage 320 conveys the respective carriage 324 and empty container packing case 50 to the respective loading end 320B where the container packing cases 50 are positioned to have loaded and capped containers 34 selectively placed into the respective cells 328. Moreover, in various embodiments, each container packing case 50 can include an identification label (not shown), e.g., a barcode label, disposed thereon that can be scanned or read by a shipping/storage box identification label scanner/reader (not shown) that is communicatively connected to the control system 32. Hence, prior to placing each container packing case 50 on a linear stage carrier 324, the operator can scan the shipping/storage box information label, via the shipping/storage box identification label scanner/reader. Box identification information obtained from the respective shipping/storage box identification label can then be stored in the control system database to track the particular loaded and capped containers 34 that are loaded into each respective container packing case 50.

Once a container packing case 50 has been conveyed to the respective loading end 320B of the respective box conveyor linear stage 320, the Cartesian robotic offload assembly 308 can begin to offload, i.e., remove, loaded and capped containers 34 from the respective pallets 42 positioned, i.e., stopped, grasped and lifted, by the main hub and auxiliary offload pallet locators 302 and 304. The offload assembly 308 includes a pair of opposing X-axis linear stages 332, a Z-axis linear stage 336 and a pick-and-place assembly 340. The opposing X-axis linear stages 332 are simultaneously controlled by the control system 32 to bidirectionally move the Z-axis linear stage 336 in the X⁺ and X⁻ directions and the Z-axis linear stage 336 is controlled by the central control system 32 to bidirectionally move pick-and-place assembly in the Z⁺ and Z⁻ directions. Hence, via the control system 32, the pick-and-place assembly 340 can be moved anywhere within a Cartesian coordinate system encompassing the main hub and auxiliary offload pallet locators 302 and 304 and the area covering each container packing case 50 when positioned at the loading end 320A of each respective box conveyor linear stage 320.

The pick-and-place assembly 340 includes a linear actuator 344 that is structured and operable, as controlled by the control system 32, to bidirectionaly move a mechanical loaded container gripping head 348 in the Y⁺ and Y⁻ directions. The mechanical loaded container gripping head 348 is operable to grasp, hold and release the loaded and capped containers 34 to offload the loaded and capped containers 34 from the respective pallets 42 and place the offloaded containers into selected container packing cases 50. More specifically, once a loaded and capped container/pallet 34/42 has been positioned by the main hub and/or the auxiliary offload pallet locators 302 and/or 304, the control system 32, controls the operation of the X-axis and Z-axis linear stages 332 and 336 to position the loaded container gripping head 348 above a loaded and capped container 34 positioned by one of the main hub or the auxiliary offload pallet locators 302 and/or 304.

Importantly, prior to a respective loaded and capped container/pallet 34/42 being positioned each of the main hub and the auxiliary offload pallet locators 302 and/or 304 each respective loaded and capped container/pallet 34/42 passed a respective one of a main hub offload pallet identification tag reader 158MO and an auxiliary offload pallet identification tag reader 158AO. Accordingly, via reading of each respective pallet identification tag 154 by the respective main hub offload pallet identification tag reader 158MO or the auxiliary offload pallet identification tag reader 158AO, the control system knows what particular loaded and capped container 34 is positioned for offloading at the respective main hub and/or the auxiliary offload pallet locators 302 and/or 304.

After the loaded container gripping head 348 has been positioned above a selected loaded and capped container 34, the control system 32 opens the loaded container gripping head 348 and lowers the opened loaded container gripping head 348, in the Y⁻ direction, around the cap and top portion of the respective container 34. The loaded container gripping head 348 is then closed to grasp the loaded and capped container 34 and the pick-and-place linear actuator 344 is operated to raise the loaded container gripping head 348 and grasped loaded and capped container 34 in the Y⁺ direction, thereby removing the loaded and capped container 34 from the respective pallet 42.

Then, via control of the X-axis and Z-axis linear stages 332 and 336, the control system 32 positions the offloaded loaded and capped container directly above a selected one of the cells 328 of a selected one of the container packing cases 50. The pick-and-place linear actuator 344 then lowers the offloaded loaded and capped container 34 into the selected cell 328 and the loaded container gripping head 348 is opened to deposit the offloaded loaded and capped container 34 in the selected cell 328. Subsequently, the loaded container gripping head 348 is raised and moved back to a position above another loaded and capped container 34 positioned for offloading at either of the main hub or the auxiliary offload pallet locators 302 or 304.

The offloading process, as described above, is continued until all subsequent loaded and capped containers 34 specified by the control system in accordance with the small object packaging project request input by the operator at the operator control station 102. Once a particular container packing case 50 and had all designated loaded and capped containers 34 deposited therein, the control system will convey the respective container packing case 50 to the handling end 320A of the respective box conveyor linear stage 320 where and operator can remove the respective container packing case 50 and replace it with an empty container packing case 50.

Referring now to FIG. 7, in various embodiments, the central control system 32 is a computer based system that generally includes at least one processor 360 suitable to execute all functions of the central control system 32 to automatically, or robotically, control the operation of the small object packaging system 10, as described herein. The central control system 32 additionally includes at least one electronic storage device 364 that comprises a computer readable medium, such as a hard drive or any other electronic data storage device for storing such things as software packages or programs, algorithms and digital information, data, look-up tables, spreadsheets and databases, e.g., the database 94 having stored thereon the look-up tables or spreadsheets described above. Furthermore, the central control system 32 includes a display 368 for displaying such things as information, data and/or graphical representations, and at least one user interface device 372, such as a keyboard, mouse, stylus, and/or an interactive touch-screen on the display 368. In various embodiments the central control system 32 can further include a removable media reader 376 for reading information and data from and/or writing information and data to removable electronic storage media such as floppy disks, compact disks, DVD disks, zip disks, flash drives or any other computer readable removable and portable electronic storage media. In various embodiments the removable media reader 376 can be an I/O port of the central control system 32 utilized to read external or peripheral memory devices such as flash drives or external hard drives.

In various embodiments, the central control system 32, i.e., the processor 360 can be communicatively connectable to a remote server network 380, e.g., a local area network (LAN), via a wired or wireless link. Accordingly, the central control system 32 can communicate with the remote server network 380 to upload and/or download data, information, algorithms, software programs, and/or receive operational commands. Additionally, in various embodiments, the central control system 32 can be structured and operable to access the Internet to upload and/or download data, information, algorithms, software programs, etc., to and from Internet sites and network servers.

In various embodiments, the central control system 32 can include one or more system control algorithms, or programs 382, stored on the storage device 364 and executed by processor 360. The one or more system control algorithms 382 utilize the small object profile information and data provided in the look-up tables and/or spreadsheets stored in the database 94 and returns the profile information and data to be included in the respective first container information label 38A. Additionally, the one or more system control algorithms 382 are executed by the processor 360 to utilize the inputs from the various pallet identification readers 158 to control the course of each container/pallet 34/42 along the main hub and auxiliary conveyors 126 and 262 and onto and off of the respective counting station conveyor 166. Furthermore, the one or more system control algorithms 382 are executed by the processor 360 to utilize various other inputs from various components and sensors of the various systems, subsystems, assemblies and subassemblies of the small object packaging system 10 to automatically operate the small object packaging system 10 as described herein.

In various embodiments, the small object packaging system can include a small object treatment station (not shown) operatively connected to the main hub conveyor assembly 14 that is structured and operable to treat the small objects with a desired treatment of coating prior to being counted at one of the counting stations 22. For example, in various embodiments, the small objects can comprise seeds, e.g., corn, soybean or cotton seeds, wherein it is desirable to apply a treatment or coating, e.g., a pesticide, insecticide, fungicide or herbicide, to the seeds prior to being counted and deposited into the containers 34 at the counting stations, as described above. Additionally, in various implementations, the treatment station can further be structured and operable to remove the seeds from the respective plants. For example, the treatment station can be structured and operable to remove corn seeds from a plurality of ears of corn, then apply a desired treatment to the corn seeds and dry the seeds. Then the treated and treated seeds can be conveyed, automatically or manually, to the hopper 184 of a selected counter 174.

Furthermore, in various embodiments, the small object packaging system 10 can include a plurality of traffic control optical sensors (not shown) mounted at various locations to the main hub conveyor assembly 14. In such embodiments, the control system 32 would execute a traffic control program or subroutine that utilizes the traffic control optical sensors to control the flow of container/pallets 34/42 as the container/pallets 34/42 are routed about the main hub conveyor 126 and routed off of and onto the main hub conveyor 126 to and from the various counting, capping and offloading stations 22, 26 and 30. Accordingly, the collisions of the various container/pallets 34/42 being processed by the small object packaging system 10, as described herein, will be avoided.

The description herein is merely exemplary in nature and, thus, variations that do not depart from the gist of that which is described are intended to be within the scope of the teachings. Such variations are not to be regarded as a departure from the spirit and scope of the teachings. 

1. A system for packaging small objects, said system comprising: a small object container marking and loading station structured and operable to singulate a plurality of small object containers, mark each singulated small object container with at least one information label, and load each marked small object container into a respective one of a plurality of container transport pallets; at least one small object counting station that is structured and operable to deposit a selected amount of small objects into each marked small object container based on data provided by the respective information label; a capping station structured and operable to singulate a plurality of container caps and secure each singulated cap onto a respective marked small object container after the selected amount of small objects have been deposited therein; an offloading station structured and operable to remove each capped small object container from the respective container transport pallet and place each removed small object container into a container packing case; and a main hub conveyor structured and operable to transport the loaded container transport pallets from the small object container marking and loading station, to the at least one small object counting station, to the capping station and to the offloading station, and then transport the empty container transport pallets back to the small object container marking and loading station.
 2. The system of claim 1 further comprising a small object treatment station structured and operable to apply a small object treatment to the small objects prior to the selected amount of small objects being deposited into each marked small object container.
 3. The system of claim 1, wherein the selected amount of small objects being deposited into each marked small object container comprises a selected volume of small objects.
 4. The system of claim 1, wherein the selected amount of small objects being deposited into each marked small object container comprises a selected number of small objects.
 5. The system of claim 1, wherein the small object container marking and loading station comprises: a container singulator structured and operable to receive a plurality of randomly oriented small object containers, singulate the small object containers, orient the singulated small object containers in a desired orientation, and dispense the oriented small object containers into a container transfer chute; and a marking and loading assembly structured and operable to receive the oriented small object containers from the container singulator, via the container transfer chute, dispose at least one container specific information label on at least one surface of each respective small object container, and load each marked small object container into a respective container transport pallet.
 6. The system of claim 5, wherein each container transport pallet includes a programmable RFID tag structured and operable to be programmed with information corresponding to information provided by the at least one container specific information label of the respective small object container loaded therein.
 7. The system of claim 1, wherein each small object counting station comprises: a small object counter structured and operable to receive a plurality of a selected type of small objects, singulate the small objects, and deposit the selected amount of the small objects into a particular small object container designated, via the respective container transport pallet RFID tag, to receive the selected amount and type of small objects; and a counting station conveyor and a diverter gate, the diverter gate structured and operable to divert selected container transport pallets off of the main hub conveyor and onto the counting station conveyor, the counting station conveyor structured and operable to transport selected container transport pallets to and from the small object counter.
 8. The system of claim 7, wherein each small object counting station further comprises a small object accumulator structured and operable to receive the selected amount of small objects from the small object counter, temporarily retain the selected amount of small objects, and deposit the selected amount of small objects into the designated small object container.
 9. The system of claim 1, wherein the capping station comprises: a cap singulator structured and operable to receive a plurality of randomly oriented container caps, singulate the container caps, orient the singulated container caps in a desired orientation, and dispense the oriented container caps into a cap transfer chute; and a robotic capping assembly structured and operable to sequentially remove the oriented caps from the cap transfer chute and install each cap on a respective container after the container has had the selected amount of small objects deposited therein.
 10. The system of claim 1, wherein the offloading station comprises: a robotic container removal and disposition assembly structured and operable to remove each capped container from the respective container transport pallet and deposit each removed container into a container packing case positioned within a deposit target zone; and a packing case transport assembly structured and operable to position at least one container packing case within the deposit target zone.
 11. A system for packaging small objects, said system comprising: a small object container marking and loading station structured and operable to singulate a plurality of small object containers, mark each singulated small object container with at least one information label, and load each marked small object container into a respective one of a plurality of container transport pallets, each container transport pallet including a programmable RFID tag structured and operable to be programmed with information corresponding to information provided by the at least one container specific information label of the respective small object container loaded therein; a plurality of small object counting stations, each small object counting station structured and operable to deposit a selected amount of a selected type of small objects into selected marked small object containers based on data stored in the respective container transport pallet RFID tag; a capping station structured and operable to singulate a plurality of container caps and secure each singulated cap onto a respective marked small object container after the selected type and amount of small objects have been deposited therein; an offloading station structured and operable to remove each capped small object container from the respective container transport pallet and place each removed small object container into a selected one of a plurality container packing cases based on data stored in the respective container transport pallet RFID tag; and a main hub conveyor structured and operable to transport the loaded container transport pallets from the small object container marking and loading station, to a selected one of the small object counting stations based on data stored in the respective container transport pallet RFID tag, from the selected small object counting station to the capping station, and from the capping station to the offloading station, and then transport the empty container transport pallets back to the small object container marking and loading station.
 12. The system of claim 11 further comprising a small object treatment station structured and operable to apply a small object treatment to the small objects prior to the selected amount of small objects being deposited into each marked small object container.
 13. The system of claim 11, wherein the selected amount of small objects being deposited into each marked small object container comprises a selected volume of small objects.
 14. The system of claim 11, wherein the selected amount of small objects being deposited into each marked small object container comprises a selected number of small objects.
 15. The system of claim 11, wherein the small object container marking and loading station comprises: a container singulator structured and operable to receive a plurality of randomly oriented small object containers, singulate the small object containers, orient the singulated small object container in a desired orientation, and dispense the oriented small object containers into a container transfer chute; and a marking and loading assembly structured and operable to receive the oriented small object containers from the container singulator, via the container transfer chute, dispose at least one container specific information label on at least one surface of each respective small object container, load each marked small object container into a respective container transport pallet, and program the respective.
 16. The system of claim 11, wherein each small object counting station comprises: a small object counter structured and operable to receive a plurality of a selected type of small objects, singulate the small objects, and deposit the selected amount of the small objects into a particular small object container designated, via the respective container transport pallet RFID tag, to receive the selected amount and type of small objects; and a counting station conveyor and a diverter gate, the diverter gate structured and operable to divert selected container transport pallets off of the main hub conveyor and onto the respective counting station conveyor, based on data stored in the respective container transport pallet RFID tag, the counting station conveyor structured and operable to transport selected container transport pallets to and from the small object counter.
 17. The system of claim 16, wherein each small object counting station further comprises a small object accumulator structured and operable to receive the selected amount of small objects from the respective small object counter, temporarily retain the selected amount of small objects, and deposit the selected amount of small objects into the designated small object container.
 18. The system of claim 11, wherein the capping station comprises: a cap singulator structured and operable to receive a plurality of randomly oriented container caps, singulate the container caps, orient the singulated container caps in a desired orientation, and dispense the oriented container caps into a cap transfer chute; and a robotic capping assembly structured and operable to sequentially remove the oriented caps from the cap transfer chute and install each cap on a respective container after the container has had the selected amount of small objects deposited therein.
 19. The system of claim 11, wherein the offloading station comprises: a robotic container removal and disposition assembly structured and operable to remove each capped container from the respective container transport pallet and deposit each removed container into a selected one of a plurality of container packing cases positioned within a deposit target zone; and a packing case transport assembly structured and operable to position each of the container packing cases within the deposit target zone.
 20. A method for packaging small objects, said system comprising: singulating a plurality of small object containers, marking each singulated small object container with at least one information label, and loading each marked small object container into a respective one of a plurality of container transport pallets utilizing a small object container marking and loading station of a small object packaging system; depositing a selected amount of small objects into each marked small object container based on data provided by the respective information label utilizing a small object counter of at least one small object counting station of the small object packaging system; singulating a plurality of container caps and securing each singulated cap onto a respective marked small object container after the selected amount of small objects have been deposited therein utilizing a capping station of the small object packaging system; removing each capped small object container from the respective container transport pallet and placing each removed small object container into a container packing case using an offloading station of the small object packaging system; and transporting the loaded container transport pallets from the small object container marking and loading station to the at least one small object counting station, to the capping station and to the offloading station, and then transporting the empty container transport pallets back to the small object container marking and loading station utilizing a main hub conveyor of the small object packaging system.
 21. The method of claim 20 further comprising applying a small object treatment to the small objects prior to the selected amount of small objects being deposited into each marked small object container utilizing a small object treatment station of the small object packaging system.
 22. The method of claim 20, wherein depositing a selected amount of small objects into each marked small object container comprises depositing a selected volume of small objects into each marked small object container based on data provided by the respective information label.
 23. The method of claim 20, wherein depositing a selected amount of small objects into each marked small object container comprises depositing a selected number of small objects into each marked small object container based on data provided by the respective information label.
 24. The method of claim 20, wherein singulating, marking and loading each small object container into a respective one of the container transport pallets comprises: receiving a plurality of randomly oriented small object containers into a container singulator of the small object container marking and loading station, then singulating the small object containers, orienting the singulated small object container in a desired orientation, and dispensing the oriented small object containers into a container transfer chute utilizing the container singulator; and receiving the oriented small object containers from the container singulator, via the container transfer chute, disposing at least one container specific information label on at least one surface of each respective small object container, and loading each marked small object container into a respective container transport pallet utilizing a marking and loading assembly of the small object container marking and loading station.
 25. The method of claim 24, wherein singulating, marking and loading each small object container into a respective one of the container transport pallets further comprises programming an RFID tag of each container transport pallet with information corresponding to information provided by the at least one container specific information label of the respective small object container loaded therein.
 26. The method of claim 20, depositing a selected amount of small objects into each marked small object container comprises receiving a plurality of a selected type of small objects in a small object counter of the small object counting station, then singulating the small objects and depositing the selected amount of the small objects into a particular small object container designated, via the respective container transport pallet RFID tag, to receive the selected amount and type of small objects utilizing the small object counter.
 27. The method of claim 26, wherein depositing a selected amount of small objects into each marked small object container further comprises receiving the selected amount of small objects from the small object counter in a small object accumulator of the small object counting station, temporarily retaining the selected amount of small objects in the accumulator, and depositing the selected amount of small objects into the designated small object container utilizing the accumulator.
 28. The method of claim 20, wherein singulating a plurality of container caps and securing each singulated cap onto a respective marked small object container comprises: receiving a plurality of randomly oriented container caps into a cap singulator of the capping station, then singulating the container caps, orienting the singulated container caps in a desired orientation, and dispensing the oriented container caps into a cap transfer chute utilizing the cap singulator; and sequentially removing the oriented caps from the cap transfer chute utilizing a robotic capping assembly of the capping station, and installing each cap on a respective container after the container has had the selected amount of small objects deposited therein.
 29. The method of claim 1, wherein removing each capped small object container from the respective container transport pallet and placing each removed small object container into the container packing case of the offloading station comprises removing each capped container from the respective container transport 